Metal Injection Molding

A.What is the metal injection molding process？

1. It is a new type of powder metallurgy near-net forming technology derived from the plastic injection molding industry. As we all know, plastic injection molding technology produces various complex shapes at low prices, but the strength of plastic products is not high. In order to improve its performance, it can be added metal or ceramic powder to plastic to obtain products with high strength and good wear resistance.

2. Metal Injection Molding (MIM) is a process in which metals are powdered, mixed, and placed into a mold to form a solid device part. There is a limited amount of mixture of powdered metal and binder material (called raw material), so metal injection molding is ideal for small parts. Applications for this process include mechanical parts, dental tools, and firearm equipment, and they often involve small, complex parts.

B.Metal Injection Molding (MIM) Process.

1. The MIM process combines the design flexibility of injection molding with the strength and integrity of precision metals to achieve low-cost solutions for extremely complex geometry parts.

2. The MIM process is divided into four unique processing steps (mixing, molding, debinding, and sintering) to achieve the production of parts, with the need for the surface treatment depending on the product characteristics.

3. The MIM manufacturing process generally includes: mixing and granulation, injection molding, degreasing, sintering, and secondary processing.

C.Main technical features of the MIM process.

1. It is suitable for the forming of various powder materials, and the product is widely used;

2. High utilization rate of raw materials, high degree of production automation, suitable for continuous mass production.

3. It can directly form small parts with complex geometric shapes (0.03g ~ 200g);

4. The dimensional accuracy of the parts is high (±0.1%～±0.5%), and the surface finish is good (roughness 1～5μm);

5. The product has a high relative density (95-100%), uniform organization, and excellent performance.

D.Commonly used surface treatment processes for MIM parts.

1. Polishing

Using mechanical, chemical, or electrochemical action, the surface roughness of the workpiece is reduced to obtain a bright and flat surface.

2. Electroplating treatment

The process of attaching a metal film to the surface of a metal or other material by electrolysis. Electroplating can prevent metal oxidation (such as rust), improve wear resistance, electrical conductivity, reflectivity, corrosion resistance (copper sulfate, etc.) and enhance aesthetics.

3. Blackening treatment

It is a common chemical treatment method to produce an oxide film on the metal surface to isolate the air and achieve the purpose of rust prevention. When the appearance requirements are not high, a blackening treatment can be used. The main components of the blackening liquid are sodium hydroxide and sodium nitrite.

E.The advantages of the MIM process.

1. MIM Injection Molding Unlimited;

PM press molding depends on high-pressure uniaxial press molding, and PM press molding is more suitable for simpler structural parts. While the use of MIM injection molding has almost no geometric restrictions, 3D design is very free.

2. MIM injection molding is more cost-effective;

If customers want to add to the cost of more expensive raw materials and equipment, you can realize savings on high-density, high-complexity structural parts that cannot be manufactured by any other traditional process. PM press molding can be a cost-effective option for simple parts, but MIM injection molding can produce precise part geometries without cutting or secondary machining, reducing overall production costs.

3. Powder material;

PM and MIM use the same base powder, and both processes can customize special parts, however, the key difference in materials is particle size. MIM injection-molded powders are much smaller and more expensive than PM press-molded powders.

4. Better physical properties;

The density of structural parts produced by MIM injection molding is different from that produced by PM press molding. The friction between the powder and the tool will make the part uneven, while the MIM injection molded part is uniform in all directions. The sintering temperature of MIM is much higher than that of PM, and the strength, toughness, and wear resistance of MIM injection molding are significantly higher.

F.Application of the MIM process.

1. Auto parts: parts for airbags, parts for car locks, parts for seat belts, car door lift systems, pinions, small parts for air conditioning systems for cars, racks in brake systems, etc. small parts in the sensor;

2. Military parts: gun parts, ammunition parts, fuze parts;

3. Computer and IT industries: such as mobile phone card trays, mobile phone structural parts, printer parts, magnetic cores, striker pins, drive parts, optical communication ceramic plugs;

4. Tools: such as drill bits, cutter heads, nozzles, spiral milling cutters, pneumatic tools, parts for fishing gear, etc.;

5. Household appliances: such as watch cases, watch chains, electric toothbrushes, scissors, golf heads, jewelry links, cutting tool heads, and other parts;

6. Parts for medical machinery: such as orthodontic frame, scissors, tweezers;

7. Electrical parts: micro motors, sensor devices;

8. Mechanical parts: such as textile machines, crimping machines, office machinery parts, etc.

G.Packing and Shipping.

1. Each product is carefully packed with bubble bags and packed in cartons. In order to cause scratches due to knocks, which will affect the quality and use of the product, we will use wooden boxes specially designed for export for packaging and transportation.

2. All products will be transported according to customer needs, such as express, air shipping, sea shipping, and railway shipping.

H.FAQs.

1. How can I get the quotation?

A:We send a quote based on drawing, quantity, weight, and material(a real sample is acceptable).

2. If I don't have the drawing, can you make a drawing for me?

A:Yes, we are able to make the drawing of your sample duplicate the sample.

3. What is your payment method?

VTooling:50% T/T advanced,50% T/T balance when sample approval.

Items bulk order:30% deposit T/T,70% balance T/T against the copy of B/L.

4. What kind of file format can you open?

A:PDF, IGS, DWG, X_T, STEP(STP).

5. What surface treatment can you do?

A:Including powder coating, sandblasting, painting, polishing, acid pickling, anodizing, enamel, zinc plating, hot-dip galvanizing, and chrome plating.

6. What is your way of packing?

A:Each product is carefully packed with bubble bags and packed in cartons. In order to cause scratches due to knocks, which will affect the quality and use of the product, we will use wooden boxes specially designed for export for packaging and transportation.

7. Do you have a sub-company overseas?

A:Yes, we have a sub-company in Michigan, USA.